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近几年，随着我厂生产规模的逐步扩大，就更加要求气体调节在生产中的稳定性和快速性，而目前传统的二次仪表已无法满足现有的控制需求。主要表现在：

　　1)过程自动化程度低，信息采集和反馈仍采用传统的二次仪表，致使数据采集缓慢、调节滞后，降低了系统运行的稳定性。

　　2)仪表内部信息储存量小，采集的压力、流量等数据无法长期保存，不便于日后生产工作的历史查询和分析。

　　3)系统可靠性低，需要配专人负责该系统的运行，造成了人工成本的上升。

　　鉴于以上三点，通过采用PLC(可编程控制器)控制系统，解决当前存在的问题。

　　1、PLC控制系统的特点及组成

　　PLC在现代工业控制领域中早己得到了广泛的应用。以PLC的控制功能而言，具有严谨、方便、易编程、易安装、可靠性高等优点。它通用性强，适应面广，特别在数字量输入/输出等逻辑控制领域有无可比拟的优点。PLC具有丰富的逻辑控制指令和应用指令，它提供高质量的硬件、高水平的系统软件平台和易学易编程的应用软件平台。另外，PLC即有自身的网络体系又有开放I/0及通讯接口，很容易组建网络并实现远程访问。

　　PLC采用Siemens公司生产的S7-300系列，由于现场的PLC系统与主控室的上位机距离较远(800米左右)，因此通讯系统需成对加装RS-485中继器，另外在现场增加TP27-10//触摸屏进行数据显示，确保系统运行的稳定性。

　　1.1系统结构及硬件配置

　　根据控制需求，CPU模块采用CPU314、数字量输入(DI)采用SM321模块，数字量输出(DO)采用SM322模块，模拟量输入(AI)采用SM331模块，模拟量输出(AO)采用SM332模块以及IM365等模块组成，IM365实现机架扩展，上位监控机采用SIEMENS公司CP5611网卡完成计算机与PLC之间的数据通讯。整个通讯网络采用MPI的通讯协议，从上位机上可对整个气体调节过程进行监控和操作。

　　1.2控制系统的功能实现

　　PLC程序的编制直接关系着供气系统能否正常工作，而程序设计的关键在于编程者对工艺系统的理解程度和程序编制技术的灵活应用。因此，在程序设计中首先考虑了供气压力调节系统的特点，将程序设计细化，分成多个程序模块，实行模块化编程。这样既可以方便的增加或删除程序模块，便于现场对工艺的调整，又可针对配套设备可控性对不同程序模块进行完善。

　　PLC的编程软件采用SIEMENS公司的SIMATICSTEP7V5.1软件平台用来完成硬件组态、地址和站址的分配以及编制整个生产过程的控制程序的。上位机监控软件采用国产软件组态王，全部采用汉化界面，便于系统的开发与操作，该系统运行于Windows2000中文平台，可实现对生产过程的全面监控，对重要参数形成历史记录，以报表或曲线的形式显示给操作人员。通过VB语言脚本，可以在主控室的上位机显示重要参数的历史趋势、实时趋势，实现压力调节的手自动切换、操作、压力的高、低限报警、流量数据的显示与累计，满足高生产率的调度需求。

　　1.3现场显示

　　现场采用TP27触摸屏进行参数显示、控制，触摸屏程序由组态软件来完成，人机界面采用中文菜单，界面友好，操作方便，功能较强，主要用于现场压力、流量、阀位的显示与操作。可作为操作人员现场操作的依据。

　　1.4工控机配置

　　工控机采用研华IPC-610，通过CP5611卡，完成S7-300PLC与工控机的通讯。主要完成下列任务：传送现场监控数据;运行监控;故障记录和排除提示;参数设置;生产数据管理和处理;图形化示教和离线编程。

　　2系统实现了供气系统的自动控制和监控，主要包括如下功能：

　　1)灵活的操作方式以及强大的系统控制功能：

　　系统可以实现上位机操作、控制柜触摸屏操作和就地手动操作;

　　2)报警功能：

　　当压力超过工艺要求，可在现场、就地实现高、低限压力报警;

　　3)简单、方便的参数设定：

　　压力调节阀的压力设定值、P、I、D等参数可以在上位机中设定。

　　2、系统控制功能

　　(1)过程控制的功能：

　　1)系统对供气压力实现了PID自动调节控制;

　　2)对所采集的模拟信号进行线性化、滤波、工程单位转换处理;

　　3)实现了流量信号的温、压补偿，提高了仪表的测量精度。

　　(2)逻辑控制

　　联锁逻辑控制实现开/关的控制，逻辑控制及用户自定义功能块等。系统实现了电磁阀控制以及参数越限报警等功能。

　　(3)人机接口

　　HMI系统中包含主工艺画面，各系统送气压力、流量，供气压力调节等多幅画面，画面直观、丰富，具备PID在线调节、在线显示调节曲线功能，包括过程量变化趋势的实时趋势曲线、历史趋势曲线。

　　(4)报表打印

　　以报表形式绘制报警记录、历史记录画面，调节间数据报表。实时趋势曲线和历史趋势曲线可随意设定时间段，打印在线趋势，历史趋势曲线。

　　3、软件设计

　　根据该系统具体情况，PLC系统软件设计过程中着重要考虑的是以下几个方面：

　　(1)数据采集及工程量转换

　　(2)PID算法

　　(3)流量温压补偿计算以及流量的累积计算

　　对于系统中的逻辑控制选用梯形图(LADDER)编程，直观、方便;对于PID回路控制流量温压补偿计算以及流量的累积计算部分则采用语句表(STL)编程，结构紧凑而又灵活。

　　PID调节是该系统中zui为重要的控制程序，因此特将PID算法作一重点介绍
 

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Process Control 9323-LOOP02ENE RSLOOP OPTIMIZER WTH RSLX

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BC646MBSS99 ME Standard Dev. Suite Site License

IC300DNT450 DeviceNet Master SmartStack Module

IC752MSC002 Mounting Clip (1) for Models 150/160/240E

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2711P-T15C22A9P PanelView Plus 7 Graphic Terminal

6SE6440-2UC11-2AA1 0.12KW

1492-JG4Q TERMINAL BLOCK

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156-B75CB1 75 A Contactor

1746-NO4I SLC 4 Point Analog Output Module

1788-CN2FFR 1788 Red CNet to FF Linking Device

193S-EEPB E1 Plus 1-5 A IEC Overload Relay

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IC647WFLARM001 PWFL -SCADA Alarm Response Management 1 User License

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IC756RDV010J-98 DV Draw Development on IRIX Op Sys, Japanese, Version 9.8

MicroLogix 1200 System 1762-IQ8 8 POINT 24 VDC SINK/SOURCE INPUT MODULE

PLC-5/1771 System 1771-M3 SERVO CONTROLLER MODULE,(1) INCLUDED W/ 1771-QC

Distributed I/O 1794-OB16 24V DC SOURCE OUTPUT MODULE, 16 POINT

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Operator Interface D6195-6.5.6 CONTROLVIEW BUILDER SPC CONFIG. USER MANUAL

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294D-FD1P5P-G1 Variable Frequency Drive

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1492-SPM3B005-N MCB Supplementary Protector 0.5 A

软启动器 3RW40242BB14

电机启动器 3VU16402CJ00

150-F361NZD SMC Flex Smart Motor Controller

1734-485ASC POINT I/O RS-485/422 ASCII Interface

1771-WN 1771 Field Wiring Arm

193-EEVF E1 Plus 55-110 A Overload Relay

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2090-CPWM7DF-10AA25 MP-Series 25m Servo Power Cable

2097-V33PR3 Kinetix 300 Servo Drive

ET-GT-5ES-3SC 4 RJ45 Ports, 1 Singlemode Fiber Port Ethernet Switch

GFK-2028 Datapanel Models 150/160 and 240E Operator's Manual

IC220MDL641 INPUT, 24VDC POSITIVE LOGIC, 2PT (REQUIRES 1 IC220TBK082)

IC647DMB001 DataMart BI Connector

IC647PWR001 Proficy Power SCADA for Small Substation

IC693MDL241CA Conformal Coated Input 24 VAC 16 points.

IC756CDV001E-97 DV Development - Compaq True64 Op Sys Addt'l User, English, Version 9. 7

MSI-MGMT-UNL-43 Unltd Site Clients - Production Mgmt-43

PLC-5/1771 System 1785-L60L EXTENDED LOCAL PLC-5/60 CONTROLLER, 64K WORD SRAM

Distributed I/O 1738-AENT ETHERNET ADAPTER

Communications 1784-KTCX15 CONTROLNET(1.5 ONLY)ISA/EISA BUS

Operator Interface 2711E-NA1 COMM CARD ADAPTER KIT FOR PV1400E (SERIES A-E)

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Support 9324-RLD25U7ENE RSLOGIX 5000 LITE ENGLISH TO PRO UPGRADE

DeviceNet Products 2711-B6C10L1 PV600 COLOR KEY&TOUCH, DNET & RS232 PRINT

RSI Software Products 9301-2SE335ZHU3R RSVIEW32 RUNTIME 1500-5K UPGRADE OUT-SUPT (ZH)

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Silver Series 2711-T14C20 PV1400 COLOR TOUCH, ENET & RS232 PRINT

HE693STP301 same as STP300E w/optical isolation, independent accel/decel

IC670MDL641 48VDC Pos./Neg. Logic Input 16 Pt. Grouped

QPJ2D101L2P QUICKPANEL 5" MONO LCD WITH CE MARK

ST-7641 STXi Expansion Field Power Distribution module, 5, 24, 48, AC 10 Amp no LED status with module ID.

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22B-B5P0C104 PowerFlex 40- 0.75 kW (1 HP) AC Drive

140DDO15310 Quantum 开关量DC输出,32点,5VDC,4组隔离,0.5A/点

284D-FVD7P6D-25-CR-EMI DeviceNet Variable Frequency Drive

E3F3-D12 30cm,扩散反射式 晶体管输出100mA电源：10-30VDC直径18mm

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6ES78220AA000YM0

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194R-J60-1753 194R Disconnect Switch

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CBL-3T-MB-30 Power/brake cable for MTR-3T50 or MTR-3T60 series servo motors. 30 feet

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IC646TDV075 75 I/O Point Development System

IC647NWV010 CIMPLICITY HMI WebView 10 Pack

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SLC/1746 System 1746-HSCE HIGH SPEED COUNTER ENCODER FOR PROGRAMMABLE CTRLR

Industrial Computers 6189V-MMA12 PANEL ADAPTER 6185-B TO 6186-M12

Application-specific products 1403-MM05B MASTER MODULE FOR POWERMONITOR

Operator Interface 2711-K6C2L1 PV600 COLOR KEY, DH485

Support 9301-2SE2500JPR SUPT REINSTATEMENT CONTRACT FOR 93012SE2500JP

Support 9380-RSB250S SUPT RENEWAL CONTRACT FOR 9380RSB250

DeviceNet Products 1734-232ASC POINT I/O RS232 ASCII INTERFACE

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Motion Control 2090-SCEP20-0 SERCOS FBR CABL,CONN,ENCLOSURE ONLY PLASTIC,20.0M

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变送器 3RS18002HQ00

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1585J-M8PBJM-3X 1585J Ethernet Media Cables

1760-LDFC PicoGFX Processor

188-K2D080 Miniature Circuit Breaker 8 A

194L-E12-2502 12A 194L Load Switch

2090-CNSSPSS-AA03 Kinetix 6000M network cable

2090-XXLF-TC3100 Kinetix Drives Line Filter

BC647OEM0101B OEM Edge Program Renewal - iFIX

GC647IPWRSTDVUNLMTM iPower Option - Std Unlmt I/O Dev Globalcare Complete part

IC200DTX850 Operator Interface with up to 200 stored messages. 4 x 20 character L CD backlight display, 8 function keys and numeric keypad.

IC646NGJ000 Johnson Controls N2 Communications

IC647IGSBSC_M IGS:Industrial Gateway Server Basic Protocols

IC670MDL642 125VDC Pos./Neg. Logic Input, 16 Point, Grouped

IC697MDL340 120 Vac Output, 2 Amp (16 Points)

IC800SLCFLYZ030 Flying lead cable to connect any 30 Watt to 750 Watt SL series amplifier I/O to a 3rd party controller. 3 meters

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Industrial Computers 6182H-12KRH6D VVCE 1250, KEYPAD, STD MEM, RIO/DH, DC

Process Control 1757-PFBUL050 PROFIBUS INTERFACE MODULE USAGE LICENSE

Operator Interface 2711P-RUL10 PANELVIEW PLUS FIRMWARE UPGRADE LICENSE

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Support 9361-VBXR SUPPORT REINSTATEMENT CONTRACT FOR 9361-VBX

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CBL-145 Cable.Allen Bradley PLC5 Channel 0 (RS-422)

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IC800SLA0201 200W, 115 VAC SL Servo Amplifier

OC647IFGLBLCLN010M-50 iFIX WebSpace 10 Additional Users (M4 key)

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1492-MCAA155 Ul489/Csa Mini Circuul489/Csa Mini Circu

1494U-HS1 1494U 30A-200A Stainless Handle

软启动器 3RW44546BC46

Safety Advanced V14 6ES7833-1FA14-0YE5 STEP 7 Safety Advanced V14 SP1 Upgrade

1585D-M4UBDM-30 Micro D-Code, QD Style Ethernet Media

1756-IR6I ControlLogix 6 Pt Isolated RTD In Module

1797-INS FlexEx Accessories

194E-E40-1753-6A 40 A 194E Load switch

2090-CFBM4E2-CATR MP-Series 0.5m Transition Cable

2090-MPPC-08S MP-Series Power Connector Kit

BC646MDA000 View Development/Runtime 8000 I/O with Proficy GlobalCare Complete

GC647ABK001 GC Spare Key

HMI-CAB-C116 CABLE UNI-TELWAY

IC641SWM706 Logicmaster 90-70 Std Comm/ 3.5 inch disks + paper docs.

IC647IFCLNTS010C iFIX iClientTS 10 Additional Users (M1Component Part)

IC660EBA103RR Thermocouple, 115Vac/125Vdc Power, Electronic Assembly

IC695PRS015 Pressure Transducer module. The serial port communicates with up to 15 Honeywell LG1237 Smart Pressure Transducer sensors. Requires firmware/software 6.5 or higher.

IC756WRE049J-99 DataViews Runtime for Windows 25-49, Per User, Japanese, Version 9.9

FlexLogix System 1794-IM8 220V AC INPUT MOD, 8 PT.

PLC-5/1771 System D1785-10.6 CONTROLNET PLC5 PROGRAM. CONTROLLERS QUICK START

Process Control 1757-PLXSIFN PLX MODICON PLC, MODBUS RTU QUICKBUILDER INTERFACE

Operator Interface 2711P-B10C6B2 PV PLUS 1000, KEY/TOUCH, RIO/DH, AC PS, EXT MEM

Support 9310-TSTNDR SUPT REINSTATEMENT CONTRACT FOR 9310TSTNDENE

Support 2705-ND1S SUPT RENEWAL CONTRACT FOR 2705ND1

Support F1785-L40BSERB FIRMWARE UPGRADE FOR 1785-L40B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300KOE RSVIEW32 WORKS 1500 (KOREAN)

RSI Software Products 9701-VWSB250JPU2 RSV SE STATION 100- 250 DISPLAY UPGRADE(JAPANESE)

RSI Software Products 9399-PLC5MAN PLC 5, 6200 SERIES MANUAL SET(FOR 5.2 REL + NEWER)

Motion Control 2098-DSD-150-SE DRIVE, 65A/150A, ULTRA3000 W/SERCOS

BC646MDB300 Logic Developer PC w/Runtime 300 I/O

IC300MIX902 8 DC Inputs (12/24vdc), 8 DC Outputs (5/12/24vdc,0.5A pos. logic with ESCP) and 4 channels Analog Inputs, voltage (0-5vdc, +/-5vdc, 0-10vdc, +/- 10vdc), 12 bit; 2 channels Analog Outputs, voltage (+/- 10vdc)

IC752SKT003RR Datapanel H Starter Kit: Includes Datapanel H (DPH000), download & communication cables, WinCfg, user & programming manuals

MTR-3S84-G-R-0-E-SRR Servo Motor with Seal

ZA06B-6120-H045 PSM-45HVi 45 kW high voltage power supply module for Alpha servos

20CC300A0ANNBNG0 PowerFlex 700H AC Drive 20C

20G1ABF265JN0NNNNN PowerFlex 755 AC Packaged Drive

25A-D043N114 PowerFlex 523 22kW (30Hp) AC Drive

2711P-T6C20A8 PanelView Plus 6 6 Color Touch AC

6SE6440-2UD22-2BA1 2.2KW

1492-JTC3K 2.5 mm Thermocouple Terminal Block

1492-XIM120-8R BUL.1667-PANELCONNECT INPMOD,INTERFACE

软启动器 3RW44241BC45

通信模块 6ES7 541-1AD00-0AB0 CM：PtP RS232，高性能通讯模块

1585-C4UB-S300 1585 Ethernet Cable

1746-OV32 SLC 32 Point Digital Output Module

1790-0V16X CompactBlock LDX 16 Expansion Block

194E-A-P22 194E 2 NO-2 NC Auxiliary Contact Block

20-PP09042 WIRE SET ASSY NON-REGENERATIVE FRONT END

2090-CSBM1DF-18AA07 Kinetix Cable Single DSL 2090-Series

20AC030F0AYNANC0 PowerFlex 70 AC Drive 30 A at 15 kW 20A

GC-8459-SI-RN SI Consignment System Renewal (12 month license)

HE200TIM100 GPS time server of HE693SER300:provides time synchronization between s eperate racks or locations